Geared gas turbine engine with oil deaerator

ABSTRACT

A gas turbine engine includes a fan section including a fan rotor, a compressor section, a turbine section including a fan drive turbine that drives the fan rotor through a gear reduction, and a lubrication system that supplies oil to the gear reduction and includes a lubricant pump that supplies a mixed air and oil to an inlet of a deaerator during operation. The deaerator includes a shell defining a cavity and a separator that separates the mixed air and oil in the cavity, delivers separated air to an air outlet of the deaerator and delivers separated oil back into an oil tank during operation. A method of designing a gas turbine engine is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/873,961, filed Jan. 18, 2018, which is a continuation of U.S. patentapplication Ser. No. 14/737,670, filed Jun. 12, 2015. U.S. patentapplication Ser. No. 14/737,670 claims priority to U.S. ProvisionalPatent Application No. 62/019,452, filed Jul. 1, 2014.

BACKGROUND OF THE INVENTION

This application relates to a gas turbine engine having a gear reductiondriving a fan wherein an oil tank has an improved deaerator.

Gas turbine engines are known and, typically, include a fan deliveringair into a bypass duct as propulsion air. The fan also delivers air intoa core engine where it passes to a compressor. The air is compressed inthe compressor and delivered downstream into a combustion section whereit is mixed with fuel and ignited. Products of this combustion passdownstream over turbine rotors driving them to rotate.

Historically, the fan rotor and a fan drive turbine rotor have beendriven at the same speed. This placed a restriction on the desirablespeed of both the fan and the fan drive turbine.

More recently, it has been proposed to provide a gear reduction betweenthe fan drive turbine and the fan rotor.

The gear reduction is a source of increased heat loss. As an example, ageared turbofan engine creates about twice as much heat loss as anon-geared turbofan engine. In addition, the weight of the engineincreases due to the weight of the gear reduction.

It has typically been the case that a designer of a gas turbine enginesizes an oil tank such that the oil can sit in the oil tank long enoughto de-aerate. On a normal turbofan engine, this had been approximatelyat least ten seconds.

SUMMARY OF THE INVENTION

In a featured embodiment, a gas turbine engine comprises a fan driveturbine for driving a gear reduction. The gear reduction drives a fanrotor. A lubrication system supplies oil to the gear reduction. Thelubrication system includes a lubricant pump supplying a mixed air andoil to a deaerator inlet. The deaerator includes a separator that forseparating oil, and delivering separated air to an air outlet, and fordelivering separated oil back into an oil tank. The separator includes amember having lubricant flow paths on both of two opposed sides.

In another embodiment according to the previous embodiment, theseparator has a splitter at an intermediate position in the inlet.

In another embodiment according to any of the previous embodiments, theair outlet has a tube extending downwardly into a deaerator shell.

In another embodiment according to any of the previous embodiments, aninlet velocity to the deaerator is less than or equal to 14 feet/second,and an exit velocity from the deaerator of the separated air is lessthan or equal to 14 feet/second.

In another embodiment according to any of the previous embodiments, adeaerator exit delivers oil into the oil tank at least 2 inches (5.08centimeters) between a freestanding oil level within the tank.

In another embodiment according to any of the previous embodiments, adwell time of oil in the tank as removed by the oil pump, on average, isfive seconds or less.

In another embodiment according to any of the previous embodiments, theoil tank may hold greater than or equal to 25 and less than or equal to35 quarts of oil.

In another embodiment according to any of the previous embodiments, theengine is rated greater than or equal to 15,000 and less than or equalto 35,000 lbs in rated thrust at take-off.

In another embodiment according to any of the previous embodiments, theoil tank holds greater than or equal to 35 and less than or equal to 50quarts of oil.

In another embodiment according to any of the previous embodiments, theoil tank is associated with an engine having greater than or equal to35,000 and less than or equal to 100,000 lbs in rated thrust attake-off.

In another embodiment according to any of the previous embodiments, thegear reduction includes a sun gear for driving intermediate gears. Oilbaffles are located circumferentially between the intermediate gears.

In another embodiment according to any of the previous embodiments, anoil capture gutter surrounds the gear reduction.

In another embodiment according to any of the previous embodiments, anoil capture gutter surrounds the gear reduction.

In another embodiment according to any of the previous embodiments, theseparator includes a scroll spiraling from the inlet to a deaeratorexit.

In another embodiment according to any of the previous embodiments, theexit includes a plurality of holes in a shell.

In another featured embodiment, method of designing a gas turbine engineincludes providing a fan drive turbine for driving a gear reduction. Thegear reduction drives a fan rotor. A lubrication system is provided tosupply oil to the gear reduction, with an oil tank, the lubricationsystem including a lubricant pump. Mixed air and oil are delivered to adeaerator inlet, the deaerator including a separator for separating oil,and delivering separated air to an air outlet, and delivering separatedoil back into an oil tank. The lubricant separator includes a memberhaving lubricant flow paths on both of two opposed sides.

In another embodiment according to the previous embodiment, theseparator is at an intermediate position in the inlet.

In another embodiment according to any of the previous embodiments, theair outlet has a tube extending downwardly into a deaerator shell.

In another embodiment according to any of the previous embodiments, theflow separator includes a scroll spiraling from the inlet to a deaeratorexit.

In another embodiment according to any of the previous embodiments, theseparator is at an intermediate position in the inlet.

These and other features may be best understood from the followingdrawings and specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a gas turbine engine.

FIG. 2 shows a portion of a cross-section of a gear reduction.

FIG. 3 shows another portion of a gear reduction.

FIG. 4 shows a lubrication system.

FIG. 5 shows a deaerator.

FIG. 6 shows internal structure of the deaerator.

FIG. 7 shows additional internal structure of the deaerator.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 20. The gasturbine engine 20 is disclosed herein as a two-spool turbofan thatgenerally incorporates a fan section 22, a compressor section 24, acombustor section 26 and a turbine section 28. Alternative engines mightinclude an augmentor section (not shown) among other systems orfeatures. The fan section 22 drives air along a bypass flow path B in abypass duct defined within a nacelle 15, while the compressor section 24drives air along a core flow path C for compression and communicationinto the combustor section 26 then expansion through the turbine section28. Although depicted as a two-spool turbofan gas turbine engine in thedisclosed non-limiting embodiment, it should be understood that theconcepts described herein are not limited to use with two-spoolturbofans as the teachings may be applied to other types of turbineengines including three-spool architectures.

The exemplary engine 20 generally includes a low speed spool 30 and ahigh speed spool 32 mounted for rotation about an engine centrallongitudinal axis A relative to an engine static structure 36 viaseveral bearing systems 38. It should be understood that various bearingsystems 38 at various locations may alternatively or additionally beprovided, and the location of bearing systems 38 may be varied asappropriate to the application.

The low speed spool 30 generally includes an inner shaft 40 thatinterconnects a fan 42, a first (or low) pressure compressor 44 and afirst (or low) pressure turbine 46. The inner shaft 40 is connected tothe fan 42 through a speed change mechanism, which in exemplary gasturbine engine 20 is illustrated as a geared architecture 48 to drivethe fan 42 at a lower speed than the low speed spool 30. The high speedspool 32 includes an outer shaft 50 that interconnects a second (orhigh) pressure compressor 52 and a second (or high) pressure turbine 54.A combustor 56 is arranged in exemplary gas turbine 20 between the highpressure compressor 52 and the high pressure turbine 54. A mid-turbineframe 57 of the engine static structure 36 is arranged generally betweenthe high pressure turbine 54 and the low pressure turbine 46. Themid-turbine frame 57 further supports bearing systems 38 in the turbinesection 28. The inner shaft 40 and the outer shaft 50 are concentric androtate via bearing systems 38 about the engine central longitudinal axisA which is collinear with their longitudinal axes.

The core airflow is compressed by the low pressure compressor 44 thenthe high pressure compressor 52, mixed and burned with fuel in thecombustor 56, then expanded over the high pressure turbine 54 and lowpressure turbine 46. The mid-turbine frame 57 includes airfoils 59 whichare in the core airflow path C. The turbines 46, 54 rotationally drivethe respective low speed spool 30 and high speed spool 32 in response tothe expansion. It will be appreciated that each of the positions of thefan section 22, compressor section 24, combustor section 26, turbinesection 28, and fan drive gear system 48 may be varied. For example,gear system 48 may be located aft of combustor section 26 or even aft ofturbine section 28, and fan section 22 may be positioned forward or aftof the location of gear system 48.

The engine 20 in one example is a high-bypass geared aircraft engine. Ina further example, the engine 20 bypass ratio is greater than or equalto about six (6), with an example embodiment being greater than aboutten (10), the geared architecture 48 is an epicyclic gear train, such asa planetary gear system or other gear system, with a gear reductionratio of greater than about 2.3 and the low pressure turbine 46 has apressure ratio that is greater than about five. In one disclosedembodiment, the engine 20 bypass ratio is greater than or equal to aboutten (10:1), the fan diameter is significantly larger than that of thelow pressure compressor 44, and the low pressure turbine 46 has apressure ratio that is greater than about five 5:1. Low pressure turbine46 pressure ratio is pressure measured prior to inlet of low pressureturbine 46 as related to the pressure at the outlet of the low pressureturbine 46 prior to an exhaust nozzle. The geared architecture 48 may bean epicycle gear train, such as a planetary gear system or other gearsystem, with a gear reduction ratio of greater than about 2.3:1. Itshould be understood, however, that the above parameters are onlyexemplary of one embodiment of a geared architecture engine and that thepresent invention is applicable to other gas turbine engines includingdirect drive turbofans.

A significant amount of thrust is provided by the bypass flow B due tothe high bypass ratio. The fan section 22 of the engine 20 is designedfor a particular flight condition—typically cruise at about 0.8 Mach andabout 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft, withthe engine at its best fuel consumption—also known as “bucket cruiseThrust Specific Fuel Consumption (‘TSFC’)”—is the industry standardparameter of lbm of fuel being burned divided by lbf of thrust theengine produces at that minimum point. “Low fan pressure ratio” is thepressure ratio across the fan blade alone, without a Fan Exit Guide Vane(“FEGV”) system. The low fan pressure ratio as disclosed hereinaccording to one non-limiting embodiment is less than about 1.45. “Lowcorrected fan tip speed” is the actual fan tip speed in ft/sec dividedby an industry standard temperature correction of └(Tram ° R)/(518.7°R)┘^(0.5). The “Low corrected fan tip speed” as disclosed hereinaccording to one non-limiting embodiment is less than about 1150ft/second.

As shown in FIG. 2, a flexible shaft 99, which is driven by the turbine46, drives a sun gear 101 which, in turn, engages and drivesintermediate gears 102. In some embodiments, the intermediate gears 102may be planet gears of a planetary epicyclic gear system. In otherembodiments, the intermediate gears 102 may be star gears of a starepicyclic gear system. The intermediate gears 102 engage and drive aring gear 103 to, in turn, drive an output shaft 106, which then drivesthe fan rotor 42. In other embodiments, a planetary gear carrier (notshown) driven by planetary gears may drive the fan shaft. Lubricant issupplied to a journal pin 108, to the intermediate gears 102 and toother locations within the gear reduction 48.

FIG. 3 shows baffles 100 which are placed circumferentially betweenadjacent planet gears 102.

A gutter 104 surrounds the gear reduction 48 and captures oil that hasleft the gear reduction. Oil from the gear reduction 48 is returned to apump 72 (See FIG. 4) or a tank 90 as shown schematically in FIG. 4. Asshown, a lubricant system 70 includes the gear reduction 48 which may bestructured as shown in FIGS. 2 and 3. Notably, complete details of theoperation of the baffle, the gutter and the other portions of the gearreduction may be as disclosed in U.S. Pat. No. 6,223,616, the disclosureof which with regard to the operation of the gear reduction isincorporated by reference.

Oil flows from an oil pump 72 to a filter 74 through a pressure reliefvalve 76 to an air/oil cooler 78 and then to a fuel/oil cooler 80. Theoil may pass through an oil pressure trim orifice 82 and back to thetank 90. Alternatively, the oil may pass through a strainer 84 and thento the gear reduction 48. Oil returning from the gear reduction and, inparticular, from the gutter, may pass back directly to the pump 72 or tothe tank 90. This is a simplification of the overall lubricant systemand, as appreciated, there may be other components.

Applicant has recognized that by utilizing baffles 100 and a gutter 104on the gear reduction 48, which may be generally as disclosed in theabove-mentioned U.S. patent, the oil need not sit in the oil tank forten seconds in order to de-aerate. Thus, the size of the tank 90 may bemade much smaller.

Conventional turbofans allow the oil to dwell in an oil tank forapproximately seven to ten seconds. The dwell time allows air bubbles toseparate from the oil to prevent foaming. With the move to a geared gasturbine engine, the oil flow volumes may effectively double. This wouldrequire a much larger oil tank, and as much as twice as large if thesame dwell time is allowed. Thus, it becomes important to reduce dwelltime.

Applicant has discovered that oil is de-aerated by the baffles 100 andgutter system and that a dwell time in the oil tank to remove airbubbles may be less than five seconds. More preferably, it may be lessthan or equal to about 3.0 seconds. This allows the use of oil tank 90to be of a size roughly equivalent to the size utilized in priornon-geared gas turbine engines. A deaerator 88 is shown incorporatedinto the oil tank 90.

The better the deaeration before the oil reaches the tank, the shorterthe dwell time that can be achieved. The disclosed deaerator achievesthese very low dwell times.

As an example, an oil tank that holds 25 to 35 quarts of oil may beutilized on a geared gas turbine engine with 15,000 to 35,000 lbs inrated thrust at take-off. Further, an oil tank may be 35 quarts to 50quarts of oil for an engine with 35,000 to 100,000 lbs in rated thrustat take-off.

FIG. 5 shows a deaerator embodiment 188. A line 190 receives an air/oilmixture such as from the pump 72. Air leaves through an air outlet 192,as shown in FIG. 4.

A plurality of oil outlets 194 are shown in an outer shell 195 of thedeaerator. An oil level 196 is shown schematically, and would be the oillevel within the oil tank 90 of FIG. 4.

As shown in FIG. 6, a flow splitter or separator 200 is provided inlineto the inlet 190 and serves to split the air/oil flow into two paths,and at an intermediate location in inlet 190. This will hasten thedeaeration of the mixed oil and air from the inlet 190. The air will beat the radially outer locations, and will pass through a tube 193 intothe air outlet 192. As shown, air outlet 192 has an end 300 extendinginto a shell 302 of deaerator 188.

As shown in FIG. 7, the oil will flow downwardly along an upper path 202of a scroll or spiral, and along a lower path 204. Although shown asvertically upper and lower sides, other opposed side orientations may beused. The inventive deaerator more quickly removes the oil, and thusfacilitates the dwell times as mentioned above.

A deaerator exit 194 delivers oil into the oil tank 90 at least 2 inches(5.08 centimeters) between a freestanding oil level 196 within the tank90. An inlet velocity to the deaerator 188 may be less than or equal to14 feet/second. An exit velocity from the deaerator 188 into the airoutlet 192 may be less than or equal to 14 feet/second.

Applicant has found that introducing the oil and air mixture into an oiltank is much “quieter,” resulting in less re-aeration when it isdelivered at least two inches below a free surface. As an example, ifthe oil were sprayed into the free surface, this could cause splashingand foaming.

As to the velocity, high velocity oil and air mixtures entering the tankmay cause re-aeration. The 14 feet/second is a very good goal to reducethe chances of re-aeration.

Although an embodiment of this invention has been disclosed, a worker ofordinary skill in this art would recognize that certain modificationswould come within the scope of this invention. For that reason, thefollowing claims should be studied to determine the true scope andcontent of this invention.

What is claimed is:
 1. A gas turbine engine comprising: a fan sectionincluding a fan rotor; a compressor section; a turbine section includinga fan drive turbine that drives said fan rotor through a gear reduction;a lubrication system that supplies oil to said gear reduction andincludes a lubricant pump that supplies a mixed air and oil to an inletof a deaerator during operation; wherein said deaerator includes a shelldefining a cavity and a separator that separates the mixed air and oilin said cavity, delivers separated air to an air outlet of saiddeaerator and delivers separated oil back into an oil tank duringoperation.
 2. The gas turbine engine as set forth in claim 1, whereinsaid separator includes a member that splits the mixed air and oil intolubricant flow paths on both of two opposed sides, said separatorincludes a scroll spiraling from said inlet to an exit of saiddeaerator, and said gear reduction includes a sun gear that drivesintermediate gears, and a ring gear.
 3. The gas turbine engine as setforth in claim 2, wherein a gear reduction ratio of said gear reductionis greater than 2.3:1.
 4. The gas turbine engine as set forth in claim3, wherein a dwell time of oil in said oil tank as removed by saidlubricant pump, on average, is five seconds or less during operation. 5.The gas turbine engine as set forth in claim 4, wherein said engine israted greater than or equal to 15,000 and less than or equal to 100,000lbs in rated thrust at take-off.
 6. The gas turbine engine as set forthin claim 4, wherein said member of said separator is at an intermediateposition in said inlet.
 7. The gas turbine engine as set forth in claim6, wherein said gear reduction includes oil baffles circumferentiallybetween said adjacent intermediate gears.
 8. The gas turbine engine asset forth in claim 7, further comprising: a bypass ratio of greater thanor equal to 10; wherein said fan section has a low fan pressure ratio ofless than 1.45; and wherein said fan drive turbine includes an inlet, anoutlet and a pressure ratio of greater than 5, the pressure ratio beingpressure measured prior to said inlet as related to pressure at saidoutlet prior to an exhaust nozzle.
 9. The gas turbine engine as setforth in claim 8, wherein said deaerator is incorporated into said oiltank, and said exit includes a plurality of oil outlets in a shell ofsaid deaerator.
 10. The gas turbine engine as set forth in claim 9,wherein said exit delivers oil into said oil tank at least 2 inches(5.08 centimeters) beneath a freestanding oil level within said tankduring operation.
 11. The gas turbine engine as set forth in claim 9,further comprising a gutter that surrounds said gear reduction such thatsaid gutter captures oil from said gear reduction during operation. 12.The gas turbine engine as set forth in claim 11, wherein said lubricantsystem includes a filter, an air/oil cooler and a fuel/oil coolerarranged such that oil flows from said lubricant pump to said filter,then flows to said air/oil cooler, and then flows to said fuel/oilcooler, and then passes back to said oil tank or said gear reductionduring operation.
 13. The gas turbine engine as set forth in claim 12,wherein oil returning from said gutter passes back directly to said pumpor said oil tank during operation.
 14. The gas turbine engine as setforth in claim 11, wherein an inlet velocity to said deaerator is lessthan or equal to 14 feet/second, and an exit velocity from saiddeaerator of the separated air is less than or equal to 14 feet/secondduring operation.
 15. The gas turbine engine as set forth in claim 14,wherein said fan drive turbine drives a compressor rotor of saidcompressor section, along with said fan rotor through said gearreduction, and a low corrected fan tip speed of less than 1150feet/second.
 16. The gas turbine engine as set forth in claim 15,wherein a dwell time of oil in said oil tank as removed by saidlubricant pump, on average, is three seconds or less during operation.17. The gas turbine engine as set forth in claim 16, wherein saidintermediate gears engage and drive said ring gear to drive an outputshaft that drives said fan rotor.
 18. The gas turbine engine as setforth in claim 17, wherein: said oil tank may hold greater than or equalto 25 and less than or equal to 35 quarts of oil; and wherein said oiltank is associated with an engine having greater than or equal to 15,000and less than or equal to 35,000 lbs in rated thrust at take-off. 19.The gas turbine engine as set forth in claim 17, wherein: said oil tankholds greater than or equal to 35 and less than or equal to 50 quarts ofoil; and wherein said oil tank is associated with an engine havinggreater than or equal to 35,000 and less than or equal to 100,000 lbs inrated thrust at take-off.
 20. A method of designing a gas turbine enginecomprising: providing a fan drive turbine that drives a fan rotorthrough a gear reduction; and providing a lubrication system thatsupplies oil to said gear reduction, with an oil tank, said lubricationsystem including a lubricant pump, said lubrication system including adeaerator; supplying a mixed air and oil to an inlet of said deaerator,said deaerator including a shell defining a cavity; separating with saidseparator the mixed air and oil in said cavity, delivering separated airto an air outlet of said deaerator, and delivering separated oil fromsaid deaerator back into said oil tank.
 21. The method as set forth inclaim 20, wherein said step of separating includes a member of saidseparator splitting the mixed air and oil into lubricant flow paths onboth of two opposed sides.
 22. The method as set forth in claim 21,wherein said separator includes a scroll spiraling from said inlet to anexit of said deaerator, and said step of separating includes causing oilto flow downwardly along upper and lower paths of said scroll.
 23. Themethod as set forth in claim 22, wherein: said gear reduction includes asun gear that drives intermediate gears, and a ring gear; a dwell timeof oil in said oil tank as removed by said lubricant pump, on average,is five seconds or less; and said deaerator is incorporated into saidoil tank.
 24. The method as set forth in claim 23, further comprising: abypass ratio of greater than or equal to 10; wherein a gear reductionratio of said gear reduction is greater than 2.3:1; and wherein said fandrive turbine includes an inlet, an outlet and a pressure ratio ofgreater than 5, the pressure ratio being pressure measured prior to saidinlet as related to pressure at said outlet prior to an exhaust nozzle.25. The method as set forth in claim 24, wherein said gear reductionincludes oil baffles circumferentially between said adjacentintermediate gears.
 26. The method as set forth in claim 25, wherein: aninlet velocity to said deaerator is less than or equal to 14feet/second; and an exit velocity from said deaerator of the separatedair into said air outlet is less than or equal to 14 feet/second. 27.The method as set forth in claim 26, wherein: said oil tank may holdgreater than or equal to 25 and less than or equal to 50 quarts of oil;and wherein said oil tank is associated with an engine having ratedgreater than or equal to 15,000 and less than or equal to 100,000 lbs inrated thrust at take-off.
 28. The method as set forth in claim 27,further comprising capturing oil from said gear reduction in a gutterthat surrounds said gear reduction.
 29. The method as set forth in claim28, wherein said member of said separator is at an intermediate positionin said inlet, and said air outlet has a tube extending downwardly intoa shell of said deaerator.
 30. The method as set forth in claim 29,further comprising: supplying oil from said lubricant pump to a filter,then to an air/oil cooler, and then to a fuel/oil cooler, and thenpassing the oil back to said oil tank or said gear reduction; anddelivering oil from said exit into said oil tank at least 2 inches (5.08centimeters) beneath a freestanding oil level within said oil tank.